Waterproof polyethylene disposable foot and sock cover

ABSTRACT

An article for keeping a foot (and potentially a sock) dry, when placed within a boot, the article comprising a non-rigid membrane impermeable to water and disposable material, and conformed to the shape of the foot so that there is little or no excess material when the article is placed over the foot (and potentially the sock, and both are) placed within the boot. The article may comprise a toe section, heel section, lower leg section, top opening, and a means for preventing the lower leg section and the top opening from falling down. Notwithstanding its disposability, the material comprising the article may be sufficiently resilient and durable for withstanding the frequent and substantial forces that the boot and foot may be subjected to during a work day at a wet construction site. The article may also allow continued use of a punctured previously-waterproof boot without the foot becoming wet.

FIELD OF INVENTION

This invention pertains to the field of articles for preventing wet feet, particularly under harsh labor conditions.

BACKGROUND OF INVENTION AND DESCRIPTION OF PRIOR ART

Numerous well-known problems arise from wet feet. For example, leaving feet in wet shoes and socks for prolonged periods may cause maceration, resulting in skin becoming sore, itchy, soft, and prone to blistering and—once the macerated skin dries out—painful cracking. Wet feet can also become colder more quickly than dry feet. Feet that are exposed to cold and damp conditions for long periods of time experience more serious problems, such as trench foot. Wet shoes and socks may also expose feet to odor-causing bacteria and fungi infections.

Certain active shoe environments of shoes are not only wet and cold, but may also require stepping through dirt and grime, which can be transferred into shoes, socks, and lower pant legs, where it may stick to and irritate a person's skin. Such harsh conditions and resulting wet and/or dirty states may frustrate the main purposes for wearing socks, such as for example keeping feet clean, providing foot-support, comfort, warmth, and preventing blistering (that may otherwise occur when the skin repeatedly rubs, sticks or slides within a shoe). When shoes are used in particularly dirty and wet environments, a person's socks may also be contaminated to such a degree that it is virtually impossible to restore them through washing to a state of perceived cleanliness.

SUMMARY OF THE INVENTION

Over the years, certain articles and methods have been utilized to try and prevent wet feet. Plastic bags, for example, have sometimes been placed over socks and inside shoes, with several critical disadvantages. For example, ordinary plastic bags are not made to cover feet and are therefore not uniquely adapted to the shape of a foot. Consequently, such bags have excess plastic material that is not only wasteful, but can fold and bunch up inside the shoe in an unequally-distributed and irregular manner, making a good fit of the foot within the shoe more difficult to achieve, and also increasing pressure at certain points of the bag inside the shoe, which can more easily lead to compromises in the plastic membrane. Such excess material may also hang loosely out of the shoe, increasing the likelihood that it be punctured, or that water or dirt particle will enter therein through a top opening. More specifically, such plastic bags are obviously not designed to hold up the top opening in an elevated position, and such a loose plastic fit—even if the bag had enough length to cover more of the leg than simply the shoe—due to the force of gravity and the absence of an effective means for maintaining the top opening in an elevated position, cannot stay extended upward covering a substantial area of the lower leg above the shoe for a substantial period of time, but rather falls back down towards the shoe, where it may loosely rest. Among the problems presented by such a design (or lack of a strategically predetermined design), such loose plastic bag-like coverings provide a lower point of entry for water and dirt particles. Once such water and dirt particles enter the plastic bag, the sock and foot can become contaminated and/or wetted by such particles. The potentially substantially impermeable plastic bag can then make matters worse, moreover, by trapping the moisture and dirt inside the bag.

In addition to makeshift plastic bags, some allegedly “waterproof” socks have been created with the objective of preventing wet feet. While some such socks may absorb less water, or dry out faster, or be designed to pull moisture away from the skin than other socks, they are often not waterproof in the true sense of the term but more accurately semi-permeable or simply “repellant” to water. Even if some existing socks do have membranes that are in fact substantially impermeable to water, such membranes may often and easily become compromised at certain spots (allowing water to pass through) or lose their waterproof (or water resistant) qualities with time and use. When such socks become more permeable to water and then become wet or immersed in water, the feet inside of course also become wet. In addition to either having membranes that become compromised or that otherwise lose their waterproof qualities over time, such waterproof socks are often made out of somewhat complex types of fabric, making them expensive to manufacture, purchase, and (once compromised or rendered less effective) replace. In addition, some such socks have other limitations, such as not being able to be worn frequently, since the needed washing (or washing using fabric softener) may substantially reduce the effectiveness and life of the socks.

Other devices, while not socks per se, have been created with similar objectives as waterproof socks, yet similarly have disadvantages. Waterproof boot rubber liners, for example, while designed to keep feet dry inside footwear, may be made from woven fabric that is permeable not only to air but also (at least eventually) to water. Like some of the aforementioned “waterproof” socks, some such boot liners lose their waterproof qualities over time. Predictably, such boot liners are also generally limited in size to the height of the boots, and do not extend much beyond the height of the boot's upper collar. In some cases this limited height may not only leave the lower leg exposed to dirt and water but may also constitute a less elevated opening into which gravity and the surface of the skin may pull water and dirt. In addition, boot liners may suffer from some of the disadvantages of shoe liners generally. By way of specific example, the boot liners are made to conform to the contours of the boot rather than a foot, and therefore the act of inserting the foot into the shoe can displace the desired position of the liner, leading to liner material bunching up within the boot in unintended spots and also lead to an improper fit of the foot within the boot.

Rubber hip waders and some waterproof boots may be substantially effective in keeping the feet dry, but, like the aforementioned “waterproof” boot liners and socks, may not be adequate for physically demanding activities in somewhat harsh conditions, such as performing work on construction sites, etc. Specifically, when performing work on many construction sites, it is a common occurrence that a worker's boots may become punctured by sharp objects, such as nails. Such puncturing often irreparably compromises the waterproof membrane, which may then allow water to seep into the boot. Due to the substantial costs of replacing said specialized waterproof boots, once the boots are punctured, some workers (at least for a time) may simply continue wearing and using the punctured boots notwithstanding their resulting wet and potentially cold feet. In addition to puncturing the boots, such nails on construction sites may also pierce the purportedly waterproof membranes of waders, boot liners, and socks that may be inside the boots, not only allowing the feet to get wet but also ruining such also potentially-expensive articles.

It would clearly be desirable if an article existed that could overcome one of more of the aforementioned disadvantages—for example, by keeping the feet dry yet not be prohibitively expensive or difficult to replace once loss of waterproof effectiveness has been experienced (whether from multiple uses or from a waterproof membrane being compromised, such as by puncturing). It would further be beneficial if such an article could allow punctured construction boots, whether or not intended to be waterproof when not in a punctured state, to be used by a person without feet becoming wet (which might avoid having to replace originally-waterproof boots).

Described herein is a waterproof polyethylene disposable foot and sock cover article for overcoming at least some of the aforementioned problems. The article may be conformed to the shape of a foot, comprising a toe section opposite to a heel section, and an ankle/lower leg section above the heel section, with a top opening above the ankle/lower leg section heel section for insertion of a foot and the lower leg (and also a sock over the foot) therein. Near the opening at the top of the sock the article may also comprise a means for preventing the top of the sock from falling down the lower leg (due to gravity and movement). In one embodiment, said means may expand and contract in the horizontal direction but not necessarily in the longitudinal direction, and may comprise elastic-like properties. Although the degree to which the means may apply inward pressure against the leg may vary, it should be sufficient to prevent the lower leg section and the top opening from falling to a lower position, and it is also preferable that it be loose enough to not be uncomfortable around and not irritate or leave marks on the skin of the lower leg. With the lower leg section and top opening nevertheless kept relatively tightly against (but not necessarily directly against) the skin and at a higher elevated point, the opportunity for water and dirt to enter is decreased. In one embodiment the means for preventing the lower leg section from falling may include a sealing mechanism against the skin to assist in preventing water and/or dirt particles from entering through the top opening. The article is furthermore configured so that, when placed over a foot and a sock, and then the article, foot and sock are placed in a boot, there may be little or no excess article material in the boot, so that the fit of the boot may only be slightly altered by the presence of the article inside the boot. Stated differently, the article described herein, in contrast to some prior art articles, may be form-fitted to the toes and heel and body of the foot, and to the lower leg, so that excess material does not bunch up in improper places, which among other advantages may decrease the likelihood that the lower leg section of the article will fall down. In some embodiments, moreover, the covering may have a predetermined size for fitting not just over the sock but also over parts of the leg. In one embodiment, the covering may have a predetermined size for also fitting over the lower pant leg, thus keeping the pant legs and socks, and feet and lower legs, dry as well as clean.

The article is further comprised of waterproof material forming a membrane that is impermeable to water. The article may in certain embodiments be comprised of a thicker gauge resilient material, less susceptible to membrane penetration. Said material may in certain embodiments comprise a high density thermoplastic polymer such as high density polyethylene (C₂H₄)_(n)H₂. Such thicker gauge and resiliency may be beneficial in certain physically-strenuous and wet environments (such as certain construction projects or certain outdoor locations), where shoes and feet may be subject to somewhat-constant and substantial external forces, and also frequent exposure to water. The gauge of the material may vary according to embodiment and preference. For example, for use in certain geographical locations accustomed to cold winter weather, a thinner gauge may be preferable in the winter to allow use with more than one layered sock within the same shoe for greater warmth of the user. On the other hand, a thinner gauge of material may not last as long in some working environment entailing somewhat harsh conditions (sometimes only lasting for one day, whereas a thicker gauge may last two to three times as long).

The article is also intentionally and strategically disposable. More specifically, the material comprising the article may be economically replaceable, such that it may be replaced numerous times by a consumer for less than the cost of replacing waterproof boots, waders, or other purportedly-waterproof liners or socks (which as mentioned above may often be comprised of woven or synthetic fabrics that are much more expensive to produce and replace). The strategic disposability of the article may be beneficial in at least several respects. First, the article is not required to be machine washed, which machine washing may be problematic and limit the frequency of use of certain prior art articles intended to keep feet dry. Rather, the article may simply be disposed of and replaced. Second, disposability also assists in avoiding the problem, common among certain prior art articles (especially those comprising a “waterproof” membrane comprised at least partially of some sort of fabric), of loss over time with use of waterproof, water repellant, and/or water resistant qualities, since the disposable article may simply and economically be replaced at the outset of or prior to any such degeneration. Third, the strategically-designed disposability of the article is anticipated to be particularly beneficial in harsh working environments where certain conditions make breaches of waterproof membranes virtually inevitable regardless of the article for keeping feet dry. For example, as mentioned above, for times when a boot and even the article described herein is punctured by a nail on a construction site, the article may be easily and affordably replaced whereas the replacement of many prior art articles are more costly. Furthermore, in one embodiment, a plurality of disposable and replaceable articles may be purchased together and distributed conveniently (from a box—in one embodiment similar to a tissue box), which might be more easily and quickly accessible in certain work environments, such as a construction site. In addition to being disposable, the article may also in one embodiment be biodegradable and environmentally-friendly.

The article may also be worn with and over socks, and may have one objective to preserve a sock in a dry state and therefore able to continue performing at least some of the intended and beneficial purposes of socks generally, including keeping moisture from settling against the skin of the foot (in contrast to some so-called “waterproof” socks that are applied directly to the skin and may nevertheless allow the feet to become wet). Stated differently, since the article may enable a sock to remain dry even in an externally wet environment, at least some of the functions of the sock are accomplishable that would otherwise not be possible with a wet sock. In addition, unlike certain waterproof socks that may be made of material that is somewhat uncomfortable against the skin, here the article allows the wearer the option of wearing socks selected according to the user's preference.

Although as mentioned the article may keep a sock (as well as a foot) dry inside the article, possibly to accommodate increased foot perspiration, the article may nevertheless comprise in one embodiment a liner for absorbing excess moisture such as sweat and also for assisting the sock in preventing the foot from acquiring undesirable odor-causing bacteria. Although the material comprising the liner may vary, in some embodiments the liner material may comprise a satin-like material, cotton, nylon, mesh, lycra, or polyester, or a combination thereof.

The above description and listed alternative embodiments are considered that of some embodiments only. It is understood that the embodiments shown in the drawings and described below are merely for illustrative purposes and not intended to limit scope. Alterations and modifications, therefore, and such further applications as would occur to those skilled in the relevant art(s), are also contemplated.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a waterproof polyethylene disposable foot and sock cover article.

FIG. 2 illustrates the article of FIG. 1 in an environment of use inside a boot and over a sock.

FIG. 3 illustrates a boot and article that have been punctured by a nail.

FIG. 4 illustrates a replacement article being conveniently distributed.

FIG. 5 illustrates a punctured boot with an intact replacement article therein.

FIG. 6 illustrates a second smaller embodiment of the article shown in FIG. 1.

FIG. 7 illustrates an article embodiment comprising an internal liner.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

“Boot” is defined herein as any covering for a foot having a sturdy sole. “Lower leg” is defined herein to either include the ankle area and in some cases the area of the leg above the ankle area.

Turning to the drawings, FIG. 1 illustrates an embodiment of a waterproof polyethylene disposable foot and sock cover article 7, conformed to the shape of a foot, and for placement over a sock 8 (that may also be placed over a foot, as shown in FIG. 2). The article 7 may comprise a toe section 9, a body section 15, and a heel section 10, and a lower leg section 11 above the heel section 10. Above the lower leg section 11 may be a top opening 12 for insertion therein of a sock 8 (and of a foot 19 as shown in FIG. 2, with the sock 8 placed over a foot 19 and lower leg 22). Near the top opening 12 may also be a means 13 for preventing the top opening 12 from falling down, which in the embodiment shown may comprise a band having elastic properties 13, allowing it to expand and contract laterally. The article 7 is further comprised of an outer membrane 14 substantially impermeable to water, comprised of a thicker gauge high density polyethylene (C₂H₄)_(n)H₂.

As shown in FIG. 2, the article 7 may enable a sock 8 and a foot 19 therein to remain dry even in an externally wet environment 16. More specifically, the article 7 may have application inside the environment of a boot 17, which boot 17 may be used in a wet environment 16, and may be used over a sock 8 (with the sock 8 inside the boot 17). Since the shape of the article 7 conforms to the shape of a foot 19, the toe section 9 may fit snugly over the toes 20 of the foot 19, and the heel section 10 tightly over the heel 21 of the foot 19, and the lower leg section 11 fitted over the lower leg 22 (with the sock 8 over all or some of said parts 20, 21 of the foot 19 and leg 22, and in between said parts 20, 21, 22 and said sections 9, 10, 11 of the article 7), so that with the article 7 placed over the foot 20 and sock 8 and within the boot 17, there is little or no excess material in the interior of the boot 18 so that the skin of the foot 19 is not aggravated by a poor fit and blisters do not form from for example a poor fit and/or sliding of the foot 19 within the boot 17. Such a tight and snug fit of the article 7 inside the boot 17 and the absence of excess material may further assist in preserving the higher elevated position of the lower leg section 11 and top opening 12. Such an advantageously elevated position may also be maintained by the assistance of the means 13 for preventing the lower leg section 11 from falling, which means 13 may substantially seal somewhat tightly (but without irritating or damages the skin of the lower leg 22) against the sock 8 and/or the lower leg 22 to assist in preventing water 16 from entering through the top opening 12.

The article 7 is also intentionally and strategically disposable and may accordingly be comprised of material that is economical to replace, which feature may be beneficial in certain circumstances and environments of use. For example, consider the harsh working conditions of certain construction environments, which may not only commonly feature puddles of water 16, but also numerous sharp and dangerous objects 23 (FIG. 3) that may inevitably puncture otherwise waterproof membranes regardless of the type of article chosen intended to keep feet dry. For example, as shown in FIG. 3, there may frequently be instances when an otherwise effective waterproof boot 29 membrane 24 may be punctured by a nail 23, breaching and leaving a hole 27 in the membrane 24 and allowing water 16 to seep through to the interior and to be exposed to both the sock 31 and foot 19. Another pair of waterproof boots 29 may not be immediately available, nor easily/economically-practicably replaceable, yet the prolonged and potentially repeated exposure of the foot 19 to water 16, especially in certain cold conditions, might lead to discomfort, blisters, macerated skin, or other health hazards, and may also result in a worker completing his or her work tasks with less than optimal efficiency as with both feet dry. In addition, where the puncture has ruptured the skin of the foot 19, continuing exposure to a wet environment of water 16 and a soaked sock 31 (FIG. 2) can lead to even greater risk of health hazard. Even where the article and article membrane 26 is worn inside the boot 29, the waterproof article and membrane 26—as well as the purportedly waterproof membrane of any prior art article for keeping feet dry—may of course also be punctured 30 so that it is irreparably breached, as shown in FIG. 3. However, in contrast to prior art articles, the article 26 may be economically, conveniently, and expeditiously replaced by another replaceable article 26. For example, FIG. 4 illustrates a dispenser 25 of replaceable articles 26, which may be bought in bulk, stored compactly and kept at a place where they may be predictably and conveniently accessible, such as a dry spot on a construction worksite. Thus, a worker 28 having a boot 29 with a waterproof membrane 24 (as shown in FIG. 3) having a puncture 27, and/or an article 26 (or prior art article) with a membrane that has been punctured 30, may simply acquire a replacement article 26 and (as shown in FIG. 4), as shown in FIG. 5, place it over a dry foot 19 and dried-out or new dry sock 31, and work may continue with the foot able to stay dry, notwithstanding the puncture 27 of the membrane 24 of the previously-waterproof boot 29, and notwithstanding water 16 seeping into the interior of said boot 29.

The precise dimensions of different article embodiments may of course vary, and replaceable articles 26 may be available in different sizes, according for example to user foot size and boot design. As shown in FIG. 6, a smaller-size embodiment 107 may comprise a shorter lower leg section 111 above a heel section 110 but may still comprise a means 113 for preventing the top opening 112 from falling down, such as a band 113 that may contract against the surface of the inner sock 8.

Other article embodiments may vary widely and may include additional features. For example, as shown in FIG. 7, one article embodiment 207 may be used (with or) without a sock and may comprise an inner liner 208 for absorbing excess moisture such as sweat and for preventing odor. Like the article 7 shown in FIG. 1, the article embodiment 207 comprising the internal liner 208 may be form-fitted to the foot 19, yet (in the particular embodiment 207 shown) the internal liner 208 may only encompass the area from the toes 20 to the heel, only along the bottom portion 209 of the foot 19. 

I claim:
 1. An article for keeping a foot and a sock placed over the foot dry, the foot having toes and a heel and above the foot there being a lower leg, when the foot and the sock are placed within a boot, the article comprising: a non-rigid, resilient membrane impermeable to water and comprised of disposable material, conformed to the shape of the foot and comprising a toe section, a heel section opposite to the toe section, a lower leg section above the heel section, and a top opening above the lower leg section; the article configured for placement over the foot and over the sock so that the toe section covers the toes of the foot and the heel section covers the heel of the foot, and the lower leg section covers at least a portion of the lower leg without the presence of excess material not conformed to the shape of the foot; whereby, with the article placed over the foot and sock, and the article foot and sock placed in the boot, water is prevented from passing through the membrane to the foot and sock and also substantially prevented from entering the top opening to the foot and sock, so that the foot and the sock remain dry while in the boot.
 2. The article of claim 1, wherein the disposable material comprises polyethylene.
 3. The article of claim 2, wherein, the disposable material comprises 100% polyethylene.
 4. The article of claim 2, further comprising, near the top opening, a means for preventing the lower leg section and the top opening from falling down when the foot and sock are placed in the article and the article and the foot and sock are placed in the boot.
 5. The article of claim 4, wherein the means for preventing the lower leg section and the top opening from falling down is expandable and contractable in the horizontal direction so that when the article is placed over the foot and the sock there is a constant contracting force at equilibrium against the lower leg.
 6. The article of claim 5, wherein the amount of contracting force is configured to keep the means for preventing the lower leg section and the top opening from falling down tight against the lower leg without resulting in skin irritation.
 7. The article of claim 6, wherein the means for preventing the lower leg section and the top opening from falling down comprises an elastic band component.
 8. The article of claim 7, wherein the lower leg comprises an ankle, and the lower leg section comprises a height so that when the article is placed over the foot and the sock and inside the boot the top opening remains situated above the ankle.
 9. The article of claim 8, wherein above the lower leg is a knee, and the lower leg section comprises a height so that when the article is placed over the foot and the sock and inside the boot the top opening remains situated between the knee and the ankle.
 10. The article of claim 3, wherein the lower leg comprises an ankle and above the lower leg is a knee, and the lower leg section comprises a height so that when the article is placed over the foot and the sock and inside the boot the top opening remains situated above the ankle and below the knee.
 11. The article of claim 10, further comprising an inner liner for absorbing moisture and reducing odor.
 12. The article of claim 11, wherein the disposable material comprises a thicker gauge.
 13. An article for keeping a foot dry after a boot having a membrane that is in its initial state impermeable to water is punctured so that the membrane is no longer impermeable to water, the foot having toes and a heel and above the foot a lower leg, the article comprising: a non-rigid, resilient polyethylene membrane impermeable to water and comprised of disposable material, conformed to the shape of the foot and comprising a toe section, a heel section opposite to the toe section, a lower leg section above the heel section, and a top opening above the lower leg section; the article configured for placement over the foot so that the toe section covers the toes of the foot and the heel section covers the heel of the foot, and the lower leg section covers at least a portion of the lower leg without there being substantial excess material not conformed to the shape of the foot; near the top opening, a means for preventing the lower leg section and the top opening from falling down when the foot is placed in the article and the article is placed in the boot with the punctured membrane; wherein, the article is configured for placement over the foot and inside the boot so that water having entering through the punctured boot membrane and into the interior of the boot is prevented from passing through the article membrane, and also water is prevented from entering the top opening, so that the foot remains dry while in the boot.
 14. The article of claim 13, wherein the fit of the article over the foot is tight enough to prevent sliding of the foot in the article with the article and foot placed in the boot.
 15. The article of claim 14, wherein a dry sock is placed over the foot, and the fit of the article is configured for covering both the foot and the sock.
 16. The article of claim 15 wherein two dry socks are placed over the foot and the fit of the article is further configured for covering the boot and both socks.
 17. The article of claim 15, wherein the disposable polyethylene material is substantially durable and comprises a gauge and density for withstanding frequent non-puncturing forces exerted on the foot and boot throughout a period of one to ten hours without the waterproof membrane of the article being compromised.
 18. The article of claim 17, wherein the means for preventing the lower leg section and the top opening from falling down is expandable and contractable in the horizontal direction so that when the article is placed over the foot and the sock there is a constant contracting force at equilibrium against the lower leg, where the amount of contracting force is sufficient to keep the lower leg section and the top opening from falling down yet not result in skin abrasion.
 19. The article of claim 18, further comprising an inner liner for absorbing moisture.
 20. The article of claim 19, wherein, except for inner liner and the means for preventing the lower leg section and the top section from falling down, the disposable material comprises 100% polyethylene. 